WO2005124907A1 - Porous electrode base material and process for producing the same - Google Patents
Porous electrode base material and process for producing the same Download PDFInfo
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- WO2005124907A1 WO2005124907A1 PCT/JP2005/011380 JP2005011380W WO2005124907A1 WO 2005124907 A1 WO2005124907 A1 WO 2005124907A1 JP 2005011380 W JP2005011380 W JP 2005011380W WO 2005124907 A1 WO2005124907 A1 WO 2005124907A1
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- resin
- porous electrode
- electrode substrate
- carbon fiber
- fibers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M8/00—Fuel cells; Manufacture thereof
- H01M8/02—Details
- H01M8/0202—Collectors; Separators, e.g. bipolar separators; Interconnectors
- H01M8/023—Porous and characterised by the material
- H01M8/0241—Composites
- H01M8/0243—Composites in the form of mixtures
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
- H01M4/8605—Porous electrodes
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M8/00—Fuel cells; Manufacture thereof
- H01M8/02—Details
- H01M8/0202—Collectors; Separators, e.g. bipolar separators; Interconnectors
- H01M8/023—Porous and characterised by the material
- H01M8/0234—Carbonaceous material
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M8/00—Fuel cells; Manufacture thereof
- H01M8/10—Fuel cells with solid electrolytes
- H01M8/1007—Fuel cells with solid electrolytes with both reactants being gaseous or vaporised
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M8/00—Fuel cells; Manufacture thereof
- H01M8/10—Fuel cells with solid electrolytes
- H01M2008/1095—Fuel cells with polymeric electrolytes
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M8/00—Fuel cells; Manufacture thereof
- H01M8/02—Details
- H01M8/0202—Collectors; Separators, e.g. bipolar separators; Interconnectors
- H01M8/023—Porous and characterised by the material
- H01M8/0239—Organic resins; Organic polymers
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/30—Hydrogen technology
- Y02E60/50—Fuel cells
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
Definitions
- the present invention relates to a porous electrode substrate and a method for producing the same.
- a porous electrode substrate is a member located between a separator and a catalyst layer in a polymer electrolyte fuel cell. This material not only functions as an electric carrier between the separator and the catalyst layer, but also distributes gas such as hydrogen and oxygen supplied from the separator to the catalyst layer and absorbs water generated in the catalyst layer and discharges it to the outside. It is required to have the function of At present, carbonaceous materials are generally considered effective.
- Patent Document 1 describes a porous electrode substrate in which organic fibers are used and pores are formed by using the fact that the organic fibers disappear by carbonization of the electrode substrate.
- the pores thus formed have a high porosity but an average diameter, and their gas permeability is too low for use in a polymer electrolyte fuel cell.
- the thickness was large and the cost was high.
- Patent Document 2 describes a method for manufacturing an inexpensive porous electrode substrate.
- the porous electrode substrate obtained by this method since the web is also oriented in the thickness direction, the conductivity and gas permeability in the thickness direction are satisfactory values, but in the thickness direction where the mechanical strength is weak. There were issues in handling, such as the oriented fibers breaking through the electrolyte membrane and making them brittle once pressed.
- Patent Document 3 describes a porous electrode substrate having a pore volume of 0.05 to 0.16 cc Zg with a pore diameter of 10 m or less in order to prevent cracking of the porous carbon substrate and increase mechanical strength. Have been. If the pore size is less than 10 / zm, water retention is It is considered that the power generation of the fuel cell, which is difficult to control due to its small size, cannot be performed sufficiently.
- Patent Document 1 Japanese Patent Application Laid-Open No. 9-278558
- Patent Document 2 Japanese Patent Publication No. WO2001Z04980 (Patent Table 2003—504822 Publication)
- Patent Document 3 WO2004Z085728
- the first and second inventions overcome the above-mentioned problems and are inexpensive, compact, and optimally suitable for assembling a cell stack.
- the object of the present invention is to provide a method for producing an electrode substrate.
- the third and fourth inventions overcome the above-mentioned problems, and are capable of smoothly supplying and discharging water and gas used for the reaction at low cost, and exhibiting cell performance. It is an object to provide an electrode substrate for use and a method for producing the electrode substrate. Means for solving the problem
- the gist of the first invention is that short carbon fibers having a fiber diameter of 3 to 9 ⁇ m dispersed in a random direction substantially in a two-dimensional plane are bound to each other with an amorphous resin carbide, Further, there is provided a porous electrode base material having a thickness of 150 m or less, wherein the short carbon fibers are crosslinked with each other by a filamentous grease carbide.
- the gist of the second invention is that after impregnating a carbon fiber paper having a carbon fiber weight of 16 to 40 g Zm 2 comprising a carbon short fiber having a fiber diameter of 3 to 9 m and vinylon fiber with a resin (preferably, a carbon fiber After impregnating carbon fiber paper of 8 to 20 gZm 2 with resin and stacking two sheets), it is a method for producing a porous electrode base material that is carbonized.
- the gist of the third invention is that short carbon fibers having a fiber diameter of 3 to 9 ⁇ m dispersed in a random direction in a substantially two-dimensional plane are bound together by an amorphous resin carbide, Further, the above-mentioned porous electrode base material is such that the short carbon fibers are crosslinked with a mesh-like resin carbide having a minimum fiber diameter of 3 ⁇ m or less.
- the gist of the fourth invention is that a short carbon fiber having a fiber diameter of 3 to 9 ⁇ m dispersed in a random direction in a substantially two-dimensional plane, and a freeness other than fibrous fiber of 400 are used.
- the porous electrode substrate having a gas permeability of a satisfactory value and excellent bending strength while being thin and inexpensive. Further, according to the method for producing a porous electrode substrate of the second invention, the porous electrode substrate can be produced at low cost.
- a polymer electrolyte fuel cell which overcomes the above-mentioned problems, is inexpensive, can smoothly supply and discharge water and gas used for the reaction, and can exhibit cell performance.
- An electrode substrate can be obtained. Further, according to the method for producing a porous electrode substrate of the fourth invention, the porous electrode substrate can be produced at low cost.
- FIG. 1 is an electron micrograph of the surface of a porous electrode substrate of the first invention.
- FIG. 2 is an electron micrograph of the surface of the porous electrode substrate of the first invention. The magnification is higher than in FIG.
- FIG. 3 is a graph showing the pore size distribution of the porous electrode substrate of the first invention.
- FIG. 4 is an electron micrograph of the surface of a porous electrode substrate of the third invention (Example 8).
- FIG. 5 is an electron micrograph of the surface of a porous electrode substrate of the third invention (Example 9).
- FIG. 6 is an electron micrograph of the surface of a porous electrode substrate of the third invention (Example 10).
- FIG. 7 is an electron micrograph of the surface of a porous electrode substrate of Comparative Example 5.
- FIG. 8 is a graph showing a pore distribution of a porous electrode substrate according to a third invention (Example 8). Comparative Example 4 was compared with the measurement result.
- FIG. 9 shows the results of evaluating the battery characteristics of the porous electrode substrate of the third invention (Example 8). This was compared with the measurement result of Comparative Example 4.
- the carbon fiber which is the raw material of the short carbon fiber used in the present invention is polyacrylonitrile-based carbon. Fibers, pitch-based carbon fibers, rayon-based carbon fibers, etc. may be used, but polyatali-tolyl-based carbon fibers are preferred.In particular, only polyacrylonitrile (PAN) -based carbon fibers can be used. Preferred because the mechanical strength of the carbon electrode substrate can be relatively high! /.
- the diameter of the short carbon fiber should be 3 to 9 / ⁇ , the production cost of the short carbon fiber, the dispersibility and the surface smoothness of the final porous electrode substrate are also required. It is preferably not more than ⁇ m.
- the fiber length of the short carbon fiber is preferably from 2 to 12 mm from the viewpoint of binding to a binder described below and dispersibility.
- ⁇ substantially dispersed in a two-dimensional plane in a random direction '' means that short carbon fibers lie so as to form substantially one surface! / That means.
- the carbonized resin is a substance formed by carbonizing the resin and binding short carbon fibers.
- phenol resin such as phenol resin, which has a strong binding force with carbon fibers and has a large residual weight during carbonization, is preferred, but is not particularly limited.
- the ratio of the resin carbide finally remaining as a carbide on the porous electrode substrate varies depending on the type of the resin and the amount of impregnation into the carbon fiber paper.
- the lower limit and the upper limit are more preferably 28% by mass and 34% by mass, respectively.
- This filament-like resin carbide has a different appearance from short carbon fibers, and the carbon constituting the filament-like resin carbide has a very good carbon orientation in the short carbon fibers. On the other hand, it is the same as the above-mentioned irregular-shaped fatty carbide.
- Figures 1 and 2 show how short carbon fibers and short carbon fibers are cross-linked with filamentary carbonized carbide.
- Filamentous carbonized carbide provides a porous electrode substrate with high mechanical strength even though it is thin. The reason for this is that the filament-like resin carbide also exerts the same reinforcing effect as the short carbon fiber, and thus the ratio of the short carbon fiber contained in the porous electrode base material can be reduced. Can be provided at cost.
- the porous electrode substrate of the present invention has pores with a radius of 5 ⁇ m or less and pores with a radius of 25 ⁇ m or more. It also has a wide pore size distribution, such as Accordingly, the porous electrode substrate of the present invention has both a function of smoothly discharging the reaction gas and generated water from the porous electrode substrate and a water retaining property of preventing the electrolyte membrane from drying and reducing the efficiency of the reaction.
- the former function is performed by large pores of 25 m or more, and the latter function is performed by relatively small pores of 5 m or less.
- Such a wide pore diameter distribution range is advantageous for achieving both functions required of a porous electrode substrate.
- the porous electrode substrate of the present invention needs to have a thickness of 150 ⁇ m or less, preferably 140 ⁇ m or less, and more preferably 130 ⁇ m or less. Porous electrode substrates with a thickness of more than 150 ⁇ m have also been used, but this is not desirable in terms of reducing the cost and size of cell stacks in the future.
- the electric resistance in the penetrating direction can be reduced as the thickness is reduced.
- the porous electrode base material has a small thickness! /, So that the flow rate of the reaction gas is easily maintained, so that the performance of the entire cell is stabilized.
- a feature of the present invention is that despite having such a thin porous electrode substrate, it has a sufficient bending rupture load as shown below.
- the porous electrode substrate of the present invention has a bending rupture load of at least 0.06 N in at least one direction even when the thickness is at most 150 ⁇ m. More preferably, even when the thickness is 130 m or less, a bending strength in at least one direction that exhibits a mechanical strength of 0.6 N or more. More preferably, it has a bending rupture load of 0.1N or more in at least one direction.
- the bending rupture load in the present invention is a value obtained by a method in accordance with JIS K-6911, and represents the strength against bending fracture.
- the bending rupture load is a force whose value changes depending on the strain rate, the distance between fulcrums, and the width of the test piece. Is adopted.
- the bending rupture load in the above one direction is 0.06 N or more.
- the basis weight (weight per unit area) of the carbon fibers needs to be 16 to 4 OgZm 2 . At this time, it is preferable that two sheets of carbon fiber paper having half the basis weight are overlapped to obtain the above basis weight.
- the short carbon fibers are not only a conductive material but also serve as a reinforcing material for the porous electrode substrate.
- the basis weight of the carbon fiber By setting the basis weight of the carbon fiber to 16 gZm 2 or more, the strength of the porous electrode It can be. Further, by setting the thickness to 40 gZm 2 or less, the structure becomes excessively dense even when the thickness is set to 150 / zm or less.
- the porous electrode substrate of the present invention can be continuously wound, which is preferable in terms of the porous electrode material / productivity and cost of the fuel cell.
- the porous electrode substrate of the present invention can be easily handled because its thickness can be reduced, and therefore, it is preferable that the substrate is continuously wound.
- the volume per unit weight of pores having pore diameters of 5 m or less is 0.20 to: LOOccZg. Is preferred.
- the pore volume of pores having a radius of 10 m or less is preferably 15% or more of the total pore volume, more preferably 20% or more.
- the porous electrode substrate for fuel cells has a function to efficiently deliver the reaction gas to the reaction section (catalyst layer). Efficiently discharges the water contained in the reaction gas and the water generated by power generation. Function is required.
- the radius of the pore is 5 m or less as a hole for temporarily taking in water when a large amount of water is generated. It is preferable that the volume per unit weight of the pores is 0.20 ccZg or more, or the pore volume of pores 10 m or less is 20% or more of the total pore volume.
- the volume per unit weight of pores with a radius of 5 m or less per unit weight is 0. It is possible that the pore volume of pores with a pore diameter of 20 ccZg or more and a pore radius of 10 m or less has 15% or more of the total pore volume. Alternatively, if the volume per unit weight of the pores having a pore radius of 5 ⁇ m or less is greater than 1. OOccZg, moisture is discharged to the outside, which is not preferable. The pore radius and the pore volume are calculated from the pressure in the measurement cell and the volume of mercury injected at that time.
- the porous electrode substrate of the present invention be wound around a paper tube having a diameter of 3 inches or less, since the equipment used for manufacturing and the packaged product can be compacted. If the paper tube size is small, it is easy to carry, which is also preferred. [0020] ⁇ Manufacturing method>
- the method for producing the porous electrode substrate of the present invention is, for example, by the following method. That is, the production of a porous electrode base material in which a carbon fiber paper consisting of short carbon fibers having a fiber diameter of 3 to 9 ⁇ m and vinylon fibers and having a basis weight of 16 to 40 gZm 2 is impregnated with resin and then carbonized. Method: Alternatively, impregnate resin into carbon fiber paper of 8 to 20 gZm2 with carbon fiber mesh consisting of short carbon fiber having a fiber diameter of 3 to 9 m and vinylon fiber, bonding two sheets, and then carbonizing. This is a method for producing a porous electrode substrate.
- Vinylon fiber is a fiber in which heat resistance and water resistance are increased by heat treating or acetalizing formyl alcohol fiber with formaldehyde.
- the vinylon fiber is decomposed and lost by carbonization, but the shape of the resin adhered therearound remains as it is, and the resin forms a filamentous carbonized material.
- the fineness of the vinylon fiber is not particularly limited, but is preferably 0.05 to 1.5 dtex.
- adhesion of resin per vinylon fiber is sufficient, and it is possible to prevent filamentous resin carbide from peeling from the porous electrode substrate after carbonization.
- By setting the fineness to 1.5 dtex or less it is possible to prevent the surface of the porous electrode substrate from becoming rough, and to make the contact between the porous electrode substrate and peripheral members favorable when the fuel cell is used. .
- the length of the vinylon fiber is not particularly limited, but is preferably about the same as the short carbon fiber used at the same time. From the viewpoint of the binding property to the binder and the dispersibility, 2 to 12 mm is preferable. By dispersing together with carbon fibers, vinylon fibers also play a role in preventing reconvergence of carbon fibers. Therefore, those having excellent affinity for water are preferable.
- the mass ratio of vinylon fibers in the carbon fiber paper is preferably 10 to 60% by mass.
- the mass ratio of vinylon fibers in the carbon fiber paper is preferably 10 to 60% by mass.
- filaments derived from vinylon fibers can be obtained.
- the reinforcing effect of the filamentary carbide is sufficient, while if it is 60% by mass or less, the balance between the filamentous carbide and the other carbides is good and the porous electrode substrate The form of the material can be satisfactory.
- the organic high molecular compound acts as a binder (glue) to hold each component in the carbon fiber paper.
- the organic polymer compound polyvinyl alcohol (PVA), polyvinyl acetate, or the like can be used.
- PVA polyvinyl alcohol
- polybutyl alcohol is excellent as a binder in the papermaking process, and therefore, is less likely to drop short carbon fibers, and thus is preferred as a binder.
- the organic polymer compound can be used as a fibrous form.
- a wet method in which short carbon fibers are dispersed in a liquid medium to form a paper, or a dry method in which short carbon fibers are dispersed in air and deposited can be applied.
- the method is preferred.
- Wet papermaking of vinylon fiber with the above amount and an appropriate amount of organic polymer material as a binder to help disperse the short carbon fibers into single fibers and prevent the dispersed single fibers from preventing convergence again Is preferred.
- a method of diffusing and dispersing in water is preferable.
- the strength of the carbon fiber paper is maintained, and the carbon fiber paper strength is prevented from peeling off and the orientation of the carbon short fiber changing during the production. Can be prevented.
- the continuous papermaking method is particularly preferred in that the control of the basis weight is easy and the productivity and the mechanical strength are considered. ,.
- the resin composition used as the resin in the present invention is a substance that remains as a conductive substance even after carbonization, and is preferably one that exhibits tackiness or fluidity at room temperature.
- Phenol resin, furan resin, epoxy resin, melamine resin, imide resin, urethane resin, aramide resin, pitch, etc. can be used alone or as a mixture. Phenol resins are preferred as they react with phenols and aldehydes in the presence of alkali catalysts. Thus, the obtained resole type phenol resin can be mentioned.
- a resol-type phenol resin is prepared by dissolving a novolak-type phenol resin which shows heat-fusing property of a solid and is formed by the reaction of phenols and aldehydes under acidic catalyst by a known method.
- a self-crosslinking type containing a curing agent such as hexamethylenediamine is preferable.
- phenols for example, phenol, resorcin, cresol, xylol and the like are used.
- aldehyde for example, formalin, paraformaldehyde, furfural and the like are used. These can be used as a mixture. These can be used commercially as phenolic resins.
- the amount of the resin adhering to the carbon fiber paper is preferably 70 to 150 parts by mass with respect to 100 parts by mass of the short carbon fiber.
- the ratio of the resin carbide in the porous electrode substrate is 25 to 40% by mass. It is necessary to adhere the resin so that 70 to 150 parts by mass of the resin must be adhered.
- the method of impregnating the carbon fiber paper with the resin is not particularly limited as long as the carbon fiber paper can be impregnated with the resin, but the resin is uniformly coated on the surface of the carbon fiber paper using a coater.
- the method, dip-nip method using a squeezing device, or the method of superimposing carbon fiber paper and resin film and transferring the resin to carbon fiber paper can be performed continuously, and the productivity and long-length method can be used. If it can be manufactured, it is preferred.
- the carbon fiber paper impregnated with the resin can be carbonized as it is. However, it is preferable to cure the resin before carbonization in order to suppress the vaporization of the resin during carbonization and to improve the strength of the porous electrode substrate.
- any technique can be applied as long as it can uniformly heat the resin-impregnated carbon fiber paper. Examples of the method include a method of laminating and heating the upper and lower surfaces of carbon fiber paper impregnated with a resin, and a method of blowing hot air from both upper and lower surfaces, and a method of using a continuous belt device or a continuous hot blast stove.
- the cured resin is subsequently carbonized. Carbonization is performed in an inert gas to increase the conductivity of the porous electrode substrate.
- the carbonization is preferably performed continuously over the entire length of the carbon fiber paper. If the electrode substrate is long, not only will the productivity of the electrode substrate be increased, but also the subsequent process of manufacturing the Membrane Electrode Assembly (MEA) can be carried out continuously, thus reducing the cost of the fuel cell. Can be greatly contributed to.
- MEA Membrane Electrode Assembly
- the carbonization it is preferable to continuously perform the baking treatment over the entire length of the carbon fiber paper in a temperature range of 1000 to 3000 ° C. in an inert treatment atmosphere.
- the carbonization is performed before the carbonization treatment performed in an inert atmosphere at a temperature range of 1000 to 3000 ° C. and before the firing in an inert atmosphere of about 300 to 800 ° C. Processing may be performed.
- the method for smoothing the carbon fiber surface is not particularly limited! However, there is a method of hot pressing with a smooth rigid plate from both upper and lower surfaces, and a method of using a continuous belt press. Above all, a method using a continuous belt press device is preferred from the viewpoint of forming a long porous electrode substrate. If the porous electrode substrate is long, not only will the productivity of the porous electrode substrate increase, but also subsequent MEMBRANE ELECT RODE ASSEMBLY (MEA) production can be performed continuously, reducing fuel cell costs. This can greatly contribute to the dagger.
- MEMBRANE ELECT RODE ASSEMBLY MEA
- porous electrode substrate having both good strength and gas permeability can be obtained.However, since the porous electrode substrate has large undulations, the porous electrode substrate has a porous structure. The contact between the porous electrode substrate and the peripheral substrate is not sufficient, which is not preferable.
- the gas generated at the time of firing may not be discharged well and the structure of the porous electrode substrate may be broken.
- the resin impregnated in carbon fiber paper is cured by sandwiching it between rigid plates and using a continuous belt device, apply a release agent in advance to prevent the resin from adhering to the rigid plate and belt, or use a carbon fiber It is preferable that the separation be performed with a release paper between the paper and the rigid plate / belt.
- carbon fibers pitch-based carbon fibers, rayon-based carbon fibers, and the like may be used, but polyacrylonitrile-based carbon fibers are preferred, and the particularly used carbon fiber is polyacrylonitrile (
- the diameter of the short carbon fiber is 3 ⁇ 9 / ⁇ , the production cost of the short carbon fiber, the dispersibility, and the surface smoothness of the final porous carbon electrode substrate are also required. It is preferably 8 ⁇ m or less.
- the fiber length of the short carbon fiber is preferably from 2 to 12 mm from the viewpoint of binding to a binder described below and dispersibility.
- ⁇ substantially dispersed in a two-dimensional plane in a random direction '' means that short carbon fibers lie so as to form substantially one surface! / That means.
- the carbonized resin is a substance formed by carbonizing the resin and binding short carbon fibers.
- phenol resin such as phenol resin, which has a strong binding force with carbon fibers and has a large residual weight during carbonization, is preferred, but is not particularly limited.
- the ratio of the resin carbide finally remaining as a carbide on the porous carbon electrode base material varies depending on the type of the resin and the amount of impregnation into the carbon fiber paper.
- the resin carbide in it is 25-40% by mass. More preferably, the lower and upper limits are preferably 28% by mass and 34% by mass, respectively.
- This reticulated carbonized carbide is different in appearance from short carbon fibers, and the carbon constituting the reticulated carbonized carbon has a very good orientation of the carbon arrangement in the short carbon fibers. Is the same as the above-mentioned resin carbide.
- Fig. 1 shows how short carbon fibers and short carbon fibers are crosslinked with a network of fatty carbides with a minimum fiber diameter of 3 ⁇ m or less.
- the conventional porous electrode substrate having high gas permeability has a problem that the catalyst layer and the polymer film formed thereon are easily dried, but the porous electrode of the present invention having a network of crosslinked fatty carbon carbides.
- the porous electrode of the present invention having a network of crosslinked fatty carbon carbides.
- reticulated carbides form many small pores, The stability of the supply and discharge of the reaction gas is also stable, so that the performance when assembled in a fuel cell can be improved.
- the porous electrode substrate of the present invention When the distribution of the pore radius is measured by the mercury porosimetry, the porous electrode substrate of the present invention has a distribution peak at a pore radius of 10 ⁇ m or less and 50 ⁇ m or more. Is preferred.
- the porous electrode substrate of the present invention not only has a function of efficiently delivering the reaction gas to the reaction section (catalyst layer), but also has a function of efficiently discharging water contained in the reaction gas and water generated by power generation. Will have.
- the presence of pores having a radius of 50 m or more is effective.To discharge water efficiently, a large amount of water is generated. It is effective to have pores with a radius of 10 ⁇ m or less as pores for temporarily taking in moisture.
- the porous electrode base material of the present invention is formed of a network of fat-carbon carbides in which large short pores formed by short carbon fibers and short carbon fibers bound by amorphous carbon carbides and short carbon fibers and carbon short fibers are formed. Since it has small pores formed by cross-linking, it is possible to have the above distribution of pore radii.
- the gas permeability in the present invention is a value obtained by a method in accordance with JIS standard P-8117, and indicates the ease with which a porous electrode substrate can release gas. It can be calculated by sandwiching a porous electrode substrate between cells with a 3 mm diameter hole, flowing 200 mL of gas through the hole at a pressure of 1.29 kPa, and measuring the time it takes for the gas to permeate.
- the gas permeability of the porous electrode substrate of the present invention is preferably 2000 mZsecZMPa or less, more preferably 1900 mZsecZMPa or less.
- the gas permeability is relatively small due to the presence of the mesh-like resin carbide.
- by setting the gas permeability of the porous electrode base material to 2000 mZsecZMPa or less it is difficult to break even if the basis weight is small, and even if the bulk density is small, the short carbon fiber does not stand in the thickness direction. It can be.
- the porous electrode substrate of the present invention be wound around a paper tube having a diameter of 3 inches or less, since the equipment used for manufacturing and the packaged product can be compacted. If the paper tube size is small, it is easy to carry, which is also preferred.
- the method for producing a porous electrode device according to the present invention is characterized in that a short carbon fiber having a fiber diameter of 3 to 9 / ⁇ dispersed in a substantially two-dimensional plane in a random direction and a filter other than a fibrous fiber are provided.
- This is a method for producing a porous electrode base material in which a fibril-like material having a water power of 00 to 900 ml, a carbon fiber paper which is strong, is impregnated with resin, and then carbonized.
- the production cost can be reduced. It is preferable that the production of the porous electrode substrate be continuously performed throughout the entire process.
- the fibril-like substance disappears due to carbonization of the resin, but the resin adhered around the fibril-like substance remains as a resin carbide and contributes to the formation of a network structure of the resin carbide.
- the fibrils have a freeness of 400 to 900 ml and are other than fibrils.
- the freeness can be adjusted.
- the water drainage during papermaking is good.
- the diameter of the fibers forming the fibril-like material can be made appropriate, and the fuel cell can be used in which the surface of the porous electrode substrate is not roughened. Good contact with other members can be maintained.
- the fibril-like material is dispersed together with the short carbon fibers, and also plays a role in preventing the re-convergence of the short carbon fibers.
- some resins generate condensed water when the resin is cured, but the fibril-like material can be expected to absorb and discharge the water. Therefore, those having excellent affinity for water are preferable.
- Specific fibrils include fibrils Synthetic pulp such as modified polyethylene fiber, acrylic fiber, and aramide fiber is used.
- the fibrillated polyethylene fiber is also preferable in terms of affinity with carbon fiber, handleability, and cost.
- the fibril-like fibrous material remains as carbon on the porous electrode substrate when the resin is carbonized, so that it is difficult to form a network-like resin carbide.
- the fibril-like material When producing carbon fiber paper by papermaking, it is essential that the fibril-like material is insoluble and does not swell in the dispersion medium during papermaking.
- a fibril-like substance that dissolves in a dispersion medium When a fibril-like substance that dissolves in a dispersion medium is used, a network-like resin carbide cannot be formed because the shape has already changed at the stage of adhering the resin.
- the surface free energy of the fiber constituting the fibril-like material is larger than the surface free energy of the short carbon fiber used from the viewpoint of efficiently forming a crosslinked structure. Since the surface free energy of the fiber constituting the fibril-like material is larger than that of the short carbon fiber, the impregnated resin adheres preferentially to the fiber, and a carbon-like crosslinked structure is easily formed after carbonization.
- the weight ratio of the fibril-like material in the carbon fiber paper is preferably from 10 to 70% by mass.
- a network-like resin carbide can be sufficiently developed, and sufficient mechanical strength and gas permeability can be imparted to the porous electrode substrate.
- the fibril-like material is preferably 10% by mass or more in order to act as a reinforcing material for overcoming an external force such as undulation generated when the resin is cured under pressure.
- the fibril-like material is set to 70% by mass or less, it is possible to prevent the porous electrode base material from easily collapsing due to insufficient resin adhering to the short carbon fiber, and preventing the thickness control from becoming difficult.
- an organic high molecular compound can be added as a constituent material of the carbon fiber paper.
- Organic polymer compounds act as binders to hold the components together in carbon fiber paper.
- the organic high molecular compound polyvinyl alcohol (PVA), polyacetic acid butyl, and the like can be used.
- PVA polyvinyl alcohol
- polyacetic acid butyl and the like can be used.
- polybutyl alcohol, polyacrylonitrile, cellulose, polyacetate butyl and the like are preferably used.
- polybutyl alcohol has excellent binding power in the papermaking process, so the short carbon fibers fall off. And is preferred as a binder.
- the organic polymer compound can be used as a fibrous form.
- Carbon fiber paper is suitably obtained by papermaking.
- a wet method of dispersing short carbon fibers in a liquid medium to form a paper, or a dry method of dispersing short carbon fibers in air and depositing them can be applied.
- the wet method is preferable.
- papermaking may be performed continuously or batchwise.
- continuous papermaking is preferred, particularly in that the weight per unit area is easily controlled and productivity and mechanical strength are considered. .
- the resin composition used as the resin in the present invention is preferably a phenol resin, a furan resin, which is a substance which exhibits tackiness or fluidity at room temperature and which remains as a conductive substance even after carbonization.
- Epoxy resin, melamine resin, imide resin, urethane resin, aramide resin, pitch and the like can be used alone or as a mixture.
- a resole type phenol resin obtained by reacting a phenol and an aldehyde in the presence of an alkali catalyst can be used.
- a novolak type phenolic resin which is formed by the reaction of phenols and aldehydes under acidic catalyst by a known method and which is a solid heat-fusible phenolic resin is dissolved and mixed into the resole type phenolic resin.
- a hardener for example, a self-crosslinking type containing hexamethylene diamine is preferable.
- phenols for example, phenol, resorcin, cresol, xylol and the like are used.
- aldehyde for example, formalin, paraformaldehyde, furfural and the like are used. These can be used as a mixture. These can be used commercially as phenolic resins.
- the amount of the resin adhering to the carbon fiber paper is such that 70 to 120 parts by mass of the resin adheres to 100 parts by mass of the short carbon fiber.
- resin should be applied so that the ratio of resin carbide is 20 to 30% by mass. To keep 70-120 parts by weight of resin.
- the method of impregnating the carbon fiber paper with the resin is not particularly limited as long as the carbon fiber paper can be impregnated with the resin, but the resin is uniformly coated on the surface of the carbon fiber paper using a coater.
- the method, dip-nip method using a squeezing device, or the method of superimposing carbon fiber paper and resin film and transferring the resin to carbon fiber paper can be performed continuously, and the productivity and long-length method can be used. If it can be manufactured, it is preferred.
- the carbon fiber paper impregnated with the resin can be carbonized as it is. However, it is preferable to cure the resin before carbonization in order to suppress the vaporization of the resin during carbonization and to improve the strength of the porous electrode substrate.
- any technique can be applied as long as it can uniformly heat the resin-impregnated carbon fiber paper. Examples of the method include a method of laminating and heating the upper and lower surfaces of carbon fiber paper impregnated with a resin, and a method of blowing hot air from both upper and lower surfaces, and a method of using a continuous belt device or a continuous hot blast stove.
- the cured resin is subsequently carbonized. Carbonization is performed in an inert gas to increase the conductivity of the porous electrode substrate.
- the carbonization is preferably performed continuously over the entire length of the carbon fiber paper. If the electrode substrate is long, not only will the productivity of the electrode substrate be increased, but also the subsequent process of manufacturing the Membrane Electrode Assembly (MEA) can be carried out continuously, thus reducing the cost of the fuel cell. Can be greatly contributed to.
- the carbonization is performed before the carbonization treatment performed in an inert atmosphere at a temperature range of 1000 to 3000 ° C. and before the firing in an inert atmosphere of about 300 to 800 ° C. Processing may be performed.
- the method for smoothing the carbon fiber surface is not particularly limited! However, there is a method of hot pressing with a smooth rigid plate from both upper and lower surfaces, and a method of using a continuous belt press. Above all, a method using a continuous belt press device is preferred from the viewpoint of forming a long porous electrode substrate. If the porous electrode substrate is long, not only will the productivity of the porous electrode substrate increase, but also subsequent MEMBRANE ELECT RODE ASSEMBLY (MEA) production can be performed continuously, reducing fuel cell costs. This can greatly contribute to the dagger.
- MEMBRANE ELECT RODE ASSEMBLY MEA
- porous electrode substrate having both good strength and gas permeability can be obtained.However, since the porous electrode substrate has large undulations, the porous electrode substrate has a porous structure. The contact between the porous electrode substrate and the peripheral substrate is not sufficient, which is not preferable.
- the gas generated at the time of firing may not be discharged well and the structure of the porous electrode substrate may be broken.
- the resin impregnated in carbon fiber paper is cured by sandwiching it between rigid plates and using a continuous belt device, apply a release agent in advance to prevent the resin from adhering to the rigid plate and belt, or use a carbon fiber It is preferable that the separation be performed with a release paper between the paper and the rigid plate / belt.
- the distance between the fulcrums was set to 2 cm, a load was applied at a strain rate of lOmmZmin, and the load when the test piece broke was measured. It is the average value of 10 test pieces.
- the pore distribution of the pore volume and the pore radius was determined by the mercury intrusion method, and the radius at which 50% of the pore volume was shown was defined as the average pore diameter of the electrode substrate.
- the mercury porosimeter used was Pore Master-60 manufactured by Quantachrome.
- the thickness of the porous electrode substrate was measured using a thickness measuring device dial thickness gauge 7321 (manufactured by Mitutoyo).
- the size of the probe at this time was 10 mm in diameter and the measurement pressure was 1.5 kPa.
- the electric resistance in the thickness direction of the porous electrode substrate (through-hole resistance) is measured by inserting a sample between copper plates, applying pressure from above and below the copper plate with IMPa, and applying a current with a current density of lOmAZcm 2. Then, it was obtained from the following equation.
- the weight ratio of the fatty carbide was calculated from the following formula, the basis weight of the obtained porous electrode base material and the basis weight of the short carbon fiber used.
- polyacrylonitrile (PAN) carbon fibers having an average fiber diameter of 7 m and an average fiber length of 3 mm and PAN-based carbon fibers having an average fiber diameter of 4 ⁇ m and an average fiber length of 3 mm are 70:30 ( (Mass ratio) were prepared.
- vinylon fiber 1. ldtex, vinylon short fiber (cutica vinylon F, manufactured by UTICA Ltd.) having a cut length of 5 mm was prepared.
- organic polymer compound short fibers of polybutyl alcohol (PVA) (VBP105-1 manufactured by Kuraray Co., Ltd., cut length 3 mm) were prepared.
- PVA polybutyl alcohol
- the short carbon fibers are dispersed uniformly in water in a slurry tank of a wet-type short net continuous papermaking machine, disintegrated into single fibers, and when sufficiently dispersed, the PVA short fibers and vinylon short fibers are reduced to 100 parts by mass of short carbon fibers. On the other hand, they were uniformly dispersed so as to be 18 parts by mass and 32 parts by mass, respectively, and sent out in a web form.
- the fed web was passed through a short netting plate, dried with a drier, and a carbon fiber paper having a basis weight of 20 g / m 2 and a length of 100 m was obtained (the basis weight of each composition is described in Table 1, the same applies hereinafter).
- the dispersion state of each fiber was good.
- the carbon fiber paper was evenly spread on a roller to which a methanol solution of phenol resin containing 40% by mass of phenol resin (Deno Nippon Chemical Co., Ltd. phenolite J-325) was attached. After contacting one surface at a time, hot air was blown continuously and dried. A resin-adhered carbon fiber paper of 32 g / m 2 was obtained. This means that 90 parts by mass of the phenol resin adhered to 100 parts by mass of the short carbon fibers.
- a continuous heating press device equipped with a pair of endless belts (a double belt press device). : DBP) to obtain a sheet having a smooth surface (sheet thickness: 110 ⁇ , width 30 cm, length 100 m).
- Preheating temperature 200 ° C in the preheating zone of this time is 5 minutes, heating ⁇ Zo over emissions at temperatures 250 ° C, pressing pressure at a linear pressure of 8. OX 10 4 N / m there were.
- the sheet was inserted between two release papers so that the sheet did not stick to the belt.
- the obtained sheet was heated in a continuous firing furnace at 500 ° C. for 5 minutes in a nitrogen gas atmosphere to cure the phenol resin and precarbonize. Subsequently, the obtained sheet was heated in a continuous firing furnace at 2000 ° C. for 5 minutes in a nitrogen gas atmosphere to be carbonized, thereby continuously obtaining an electrode substrate having a length of 100 m. It was wound up on a paper tube. Although thin, it was an electrode substrate that was smooth and excellent in handling, immediate bending strength and gas permeability. The evaluation results are shown in Tables 2 and 3.
- Fig. 11 shows an SEM photograph and Fig.
- a porous electrode substrate having a smooth surface was obtained in the same manner as in Example 1, except that the ratio of the short carbon fibers was changed to 50Z50 (mass ratio).
- the evaluation results are shown in Tables 2 and 3.
- a porous electrode substrate having a smooth surface was produced in the same manner as in Example 1 except that vinylon fibers were replaced with 0.6 dtex and vinylon staple fibers having a cut length of 5 mm (unitika vinylon F manufactured by UTICA Co., Ltd.). Got.
- the evaluation results are shown in Tables 2 and 3.
- a porous electrode substrate having a smooth surface was obtained in the same manner as in Example 1, except that only PAN-based carbon fibers having an average fiber diameter of 4 / zm and an average fiber length of 3 mm were used as the short carbon fibers.
- the evaluation results are shown in Tables 2 and 3.
- the average fiber diameter of 7 / ⁇ ⁇ using the average fiber length of only PAN-based carbon fibers of 3 mm, except that no ⁇ Ka ⁇ vinylon fibers, in the same manner as in Example 1, 15 g / m 2 Of carbon fiber paper was obtained.
- 100 parts by mass of phenol resin was adhered to 100 parts by mass of carbon fiber short fibers to obtain 28 gZm 2 of resin-adhered carbon fiber paper.
- Example 1 Thereafter, an attempt was made to obtain a porous electrode substrate in the same manner as in Example 1. However, under the same conditions as in Example 1, after heating and pressurizing, countless screens entered.When the preheating temperature was increased to 200 ° C and the power was increased to 230 ° C, the screen disappeared. Then, firing was performed in the same manner as in Example 1 to obtain a porous electrode substrate. The obtained porous electrode substrate was brittle and difficult to handle. Tables 2 and 3 show the evaluation results. FIG. 2 shows the pore distribution of the porous electrode substrate. Since the peak is sharp and the pore volume of pores of 10 m or less is only 19% of the total pore volume, it is expected that the performance will be low even when incorporated into a cell where the generated moisture is difficult to control. .
- the porous electrode base material became stronger due to the increased basis weight, but became brittle and difficult to handle. Tables 2 and 3 show the evaluation results.
- PAN Polyacrylonitrile
- organic polymer compound short fibers of polybutyl alcohol (PVA) (VBP105-1 manufactured by Kuraray Co., Ltd., cut length 3 mm) were prepared.
- PVA polybutyl alcohol
- polyethylene pulp manufactured by Mitsui Irigaku Co., Ltd., SWP freeness 450 ml, pulp freeness test method of JIS P8121 (1) measured by Canadian standard type
- the carbon short fibers are uniformly dispersed and defibrated in water in a slurry tank of a wet short net continuous paper making apparatus, and when sufficiently dispersed, 13 parts by mass of PVA short fibers and polyethylene pulp are added to 100 parts by mass of carbon short fibers. Parts and 38 parts by mass, and then distributed.
- the fed web was passed through a short netting board and dried with a dryer to obtain a carbon fiber paper A having a basis weight of 28 g / m 2 and a length of 100 m (the basis weight of each composition is described in Table 1, the same applies hereinafter). Dispersion is good and it is good.
- carbon fiber paper A is uniformly applied to a roller to which a 40% by mass methanol solution of phenol resin (Phenolite J-325, manufactured by Dainippon Ink and Chemicals, Inc.) has adhered. Then, hot air was blown continuously and dried. A resin-adhered carbon fiber paper having a basis weight of 47 g / m 2 was obtained. At this time, 100 parts by mass of the phenol resin was adhered to 100 parts by mass of the short carbon fibers.
- phenol resin Phhenolite J-325, manufactured by Dainippon Ink and Chemicals, Inc.
- the sheet is cured in a continuous firing furnace at 500 ° C for 5 minutes in a nitrogen gas atmosphere, pre-carbonized, and then continuously fired at 2000 ° C in a nitrogen gas atmosphere. , And continuously carbonized to obtain an electrode substrate having a length of 100 m, which was wound around a cylindrical paper tube having an outer diameter of 30 cm. The dispersion of the carbon fibers was good, and it was easy to handle and use as an electrode substrate.
- the evaluation results are shown in the table.
- Example 6 Except for the conditions described in Table 4, the same operation as in Example 6 was performed to obtain a porous electrode device having a smooth surface.
- Table 5 shows the evaluation results.
- FIG. 8 shows the pore distribution of the porous electrode substrate obtained in Example 8. Two peaks are observed due to the presence of the reticulated carbide, and the distribution range of the pores is widened. Further, a single cell of a polymer electrolyte fuel cell was prepared using the porous electrode substrate, and the cell characteristics were evaluated. As a result, stable performance was obtained under the humidifying condition of 80 ° C. The results are shown in FIG.
- a carbon fiber paper having a basis weight of 26 g / m 2 and a length of 100 m was obtained in the same manner as in Example 7, except that the amount of polyethylene pulp added was changed to 0. The dispersion state was good.
- a resin-attached carbon fiber paper having a basis weight of 48 gZm 2 was obtained in the same manner as in Example 7.
- an electrode substrate was obtained in the same manner as in Example 7. The gas permeability is excellent. It is brittle, and the fibers fall off.
- the sample had low resistance and high gas permeability. However, when the battery characteristics were compared with the sample of Example 3, the performance was very high. As can be seen from the pore distribution, it is considered that this result was obtained because the electrode base material has few small pores and the water management ability in the electrode is not so high.
- An electrode substrate was obtained in the same manner as in Example 1, except that wood pulp (freeness: 550 ml) was used as the fibril-like material. Although the electrode substrate had a smooth surface, the force can also be seen from Fig. 2. This electrode substrate has few small holes, so the ability to manage the water in the electrode is not very high, so the performance when used as a battery Is not very high. The evaluation results are shown in the table.
- An electrode substrate was obtained in the same manner as in Comparative Example 3, except that polyacrylonitrile (PAN) -based carbon fibers having an average fiber diameter of 4 m and an average fiber length of 3 mm were used as the short carbon fibers. Force that was an electrode substrate with a smooth surface This electrode substrate is small and has few pores, so the ability to manage water in the electrode is not very high, so the performance when used as a battery is not very high. The evaluation results are shown in the table.
- PAN polyacrylonitrile
- An electrode substrate was obtained in the same manner as in Comparative Example 3, except that hemp pulp (freeness 350 ml) was used as the fibril-like material. Force that was an electrode substrate with a smooth surface This electrode substrate has a small number of small holes, so the ability to control the water content in the electrode is not very high, so the performance of a battery is not very high. The evaluation results are shown in the table.
- the first invention and the second invention overcome the problems of the prior art, and are inexpensive, compact, and optimal for a polymer electrolyte fuel cell electrode assembly in a cell stack. This is a method for producing a base material.
- the porous electrode substrate of the third invention is inexpensive and smoothly supplies and discharges water and gas used for the reaction, and is capable of exhibiting cell performance.
- An electrode substrate can be obtained, and the fourth invention is a method for inexpensively producing this porous electrode substrate.
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Abstract
Description
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US11/630,368 US20080038589A1 (en) | 2004-06-21 | 2005-06-21 | Porous Electrode Base Material and Production Method Thereof |
EP05753364.8A EP1788651B1 (en) | 2004-06-21 | 2005-06-21 | Porous electrode base material and process for producing the same |
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CN101798774A (en) * | 2010-04-01 | 2010-08-11 | 东华大学 | Carbon fiber paper and preparation method thereof |
JP2011146373A (en) * | 2009-12-17 | 2011-07-28 | Toray Ind Inc | Manufacturing method of gas diffusion electrode base material |
WO2016072414A1 (en) * | 2014-11-04 | 2016-05-12 | 三菱レイヨン株式会社 | Porous electrode substrate, membrane/electrode assembly using same, and solid polymer fuel cell using same |
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US8343452B2 (en) * | 2006-03-20 | 2013-01-01 | GM Global Technology Operations LLC | Acrylic fiber bonded carbon fiber paper as gas diffusion media for fuel cell |
CA2751292C (en) | 2009-02-04 | 2016-09-06 | Mitsubishi Rayon Co., Ltd. | Porous electrode substrate, method for producing the same, membrane electrode assembly, and polymer electrolyte fuel cell |
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US8574758B2 (en) | 2009-07-08 | 2013-11-05 | Mitsubishi Rayon Co., Ltd. | Porous electrode substrate and method for producing the same |
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JP6277653B2 (en) * | 2013-10-03 | 2018-02-14 | 三菱ケミカル株式会社 | Method for producing porous electrode substrate |
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Also Published As
Publication number | Publication date |
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EP1788651A4 (en) | 2009-07-29 |
EP1788651B1 (en) | 2019-04-03 |
EP1788651A1 (en) | 2007-05-23 |
US20080038589A1 (en) | 2008-02-14 |
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